Electrical connection, method, and apparatus

March 27, 1956

L. B. PAULES

2,740,102 apparatus

ELECTRICAL CONNECTION, METHOD, AND

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BY

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2,740,102

Patented Mar. 27, 1956 _T 2 “«sr.'Sis³r™ “ °·¹·’ s^d , i · * ’ In prior pressure-crimDino- me^riQ Mr

Ex?^?S£a“^“—?S3 vide ϊ ™X'X'X “« Γ»this crimXr X ^{means for} impressively applying

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Prior toXddSnatV ^{CUred m P}°^{sition at ail tim}es ^P c JI ^{d d ng the} crimping operation.

Furthermore it is an object of this invention to mo of * “Λ ^{°^r tmpressing a crimp across the seam 5 ’ terminal. Prior to the teaching of this m &lt;eat.cn n was common practice to deform the surfaces opXcausX ‘° X.,^Seam· ™s tended to cam the seam ope,, causmg a f_{aiJure of the terminal The}X X X ^{this cond}ition by causing the deformation to be made across the seam.

accomplish these objects and gain other advantages by providing a crimping means which has three die 1 XX.d”?^{d ,iu}?™^il 3«» this X X 1°T? ^{portlon and} yet closely abut \ ^{1 st durlng} crimping and which are XX ^aole.^to compress the material of the wire-grippiiw ferrule portion, and of its insulation sheath if there tmmtoal ^lncr®^{asing the latera}l dimension of the tuimaal Further advantages are gained by crimping the feiriLe or ferrule and insulation sheath, into a pfane pvipeadicular to the lateral axis of the terminal 1 e into a piane perpendicular to the plane of the side element and paradel to the longitudinal axis of the ferrule termhiaL ^{W a}“ ^{lsOmetric view} °^{f a} typical flag-type accoX^X ^Simiiar J^iew of such a terminal insulated according to the invention of Trueman R. Betts.

Figure 3 is a top plan view of a terminal of the type _C;_;X’^{n FlgUre 2 as d wouId a}PP^ear after it has been cnmp^d vnto a wire according to old methods

Figure 4 is a cross-sectional view of a connector of the type shown m Figure 2 while being crimped by opposed cnmpmg toes in a manner which produces a connection 2 olrnwn m pigure 3; this view can be considered as taken m pa,t at die line 4—4 of Figure 3 and enlarged 50%.

figure ο is an isometric view of a terminal of the tvpe 5„·° ^{2 tas te} “·»^ά · s accci cling to this invention.

X”^{6 6 is a tOp plan view cf the} connection shown in

A **X C *2 ·

Figure .7 is a view similar to Figure 4 but representing th„ cnmping of a connection of the type shown in Figures . Figure 8 is an isometric view of crimping dies embodv4^Dgand ^S₇^mVentlOn’ ^{draWn to the en!arged} stale of Figures

Figure 9 is an isometric view of a terminal of the trere shown m Figure 2 after it has been crimped onto a wire οί2ώ£ηη^&gt;βΓ^{6Πί!βη bUt Wkh crimping die surfa}«s

2,740,102

ElECTBICAl CONNECTION, METHOD, AND b^a·’ ΐ·*” ‘° ΛΙκη».

Of New Jersey ’ ^Harnsbur&amp; a corporation

Appffi_cati_0n Au_{gusi 25&gt; 19S1&gt; Ser}._{ai 243j62j}

Claims. (Cl. 339—276) tyXitiXre^{D relateS} -^{t0 electrical} connections of the

Jin“^S ““ ? ° “”®“ '«““il on”™ previously i isX _nfo Γ ° * ^COnductive ™re referred X , ^{11 Such} compression is usually

XX’ S assembly may’fcfoZ strength as ns _tⁿha^Ct of X ^{haS a tensiIe}W low electrical reside ^C“^ed’ “^d eXXXXX ^terminals been standard in XXXX ^{for a great} “any years, and in recent ^eac? ^t0 , ^{atten tbe} ferrule so as to increase its idth and to that extent increase the necessary spacing stresses during crimping.

^{flaS ierminals are} ordinarily used because of space limitations, since they bring the wire to a binding post etc.., in substantially tangential relation, and it is therefore desiraole that the ferrule take up as little £&gt;m as possible elemenM’XS¹ X °^f X ^bi”^{ding post hole in tbe} “sSe oii ^v J J^ch tvrm I use here as a general term for Sle^C°portionⁿ)^{g eXtend}“^{g lateral}ly from- the fer. . ^x Recently in order to permit more cnmpact wiring arrangements without danger _of short cir' :xsrr·’'° sx With nX / X® ^present mvention is applicable tw ίίΧΤ ς X ^lnX^{ated and} uninsulated flagtj^ tremmJs. Such insulated connectors, useful with ti~ present invention, are disclosed and claimed in an application of Trueman R. Betts, Serial No. 183 615 f ed September 15, 1950. Such insulation permits locatmg terminals m close relation without danger of conpS ^by ^aX^ental Station of the terminal on its binding po.t, bui die insulation itself adds to the over-all diam?

ecer ox the terrule, so that such insulating may acSaflv be the limiting factor for very close spacingrfterSS v/nich it would otherwise make possible

X ^{1S ihere}f^{ore a} major object of this invention to pro“,.-X-^ans tor making a flag-type wire-terminating coniiecti^n m wmch the lateral width of the connection (i e measured perpendicular to the axis of the ferrule and parairel to the plane of the side element) can be reduced without destroying the mechanical and electrical security ^{* * * * * * * * * * * * * * * 70}of me connections made therewith, and even with enhanced security.

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2,740,102

Λ and 6, which latter figures show a similar terminal after being crimped according to this invention. A crimp similar to the Buchanan crimp of Figure □ isi usedbm. the transverse spreading resulting therefrom has been c. reted into the vertical plane where it is, unobje-tionabl-, because the binding post and nut assemoly usually has a height considerably greater than the height or a terminal crimned according to this invention.

Figure 7 shows a preferred embodiment or my invention in first, second and third crimping dies n3, 3o and 36 ;»s-ectivetv which permit the compacting of the rerrule 22and insulation sheath 28 toward the vertical pi^ne. Dis 33 and 35 have curved surfaces 37 and 39 of less toan half the height of the surface 40 of die 36 m order tna» the proper crimping relationship of opposeu oies may be maintained. During crimping, dies 33 and o5 ana die pp are moved relatively together; dies 33. and 35 are mcvea in parallel paths toward die 36, or dies 33 am.are fixed in position and die 36 is brought toward them, or 20 a combination of these two movements may take place.

In any case, dies 33 and 35 should, upon taeir stiriaces 37 and 39 engaging the sheath 28, be so spaced apaxo that the tongue portion 24 fits rather closely in between them. Thus die surfaces 37 and. 39 can .confine the m»5 inflation sheath material and press it away from tne tongue 24 bv virtue of the extrusion normally attendant on thorough crimping. In this instance the.extrusion occurs as a slight vertical and longitudinal flowing of tne pla^c from beneath the crimping die surfaces.

SO A further advantage of the: instant invention lies m the relationship of parts that provides a “keying effect between the terminal and dies. As shown in Figures / and 10, the tongue 24 is originally positioned m the slot in one die. This insures proper positioning of the. termi«5 nal relative to the die at all times during the crimping operation Thus the terminal must be correctly inserted and is retained in the correct position while the crimp is being made.

: It is also noted that the teaching of the mvention.pro.10 vides a crimp across the seam 26 of the ferrule vtugure

7' rather than at 90° to the seam (Figure 4). Thus the seam is deformed to provide a secure crimp rather than causing it to be split open due to extrusion.

As shown in Figures 3, 5, 6 and 8, the die surfaces of the Buchanan crimp are actually used as reversed duplicate pairs of each surface. The reference to firs», second and third die surfaces ignores this duplication, as the la ter is not related to the invention but comprises an a-vant^eeous form of the Buchanan crimping dies.

The closeness of the fit between adjacent edges or tne d'e surfaces 37 and 39 against the tongue portion -./ of a terminal being crimped is important, .as any appreciable clearance might permit some of the msulahou -“'atertai of a crimpably-insulated terminal to extrudover the adjacent areas of the tongue portion. This fit ⁵³ should be just loose enough to permit easy insertion and removal of the side element of a connector.

For similar reasons it is important that me dies -&gt;3 and 35 are either fixed while the die 30 is mofec towd them, or that they are moved so that the adjacent edges of the die surfaces 37 and 39 are maintained clv,ely adjacent to the faces of the tongue portion 24 dunn_Bcrimping; in short, if the side element, has parallel fa-es, surfaces 37 and 39 should be moved m parallel r^e’^aboaship if they are moved at all. An advantageous ex. 65 ment is, therefore, that shown in. Figure 8 wherein surfaces 37 and 39, associated with dies 3o and -5 je rigidly held in spaced relationship to one anothy by th integral attachment of dies 33 and 35 to a die-bearin member 44. This advantageous, successful embodiment 70 mav consist of dies 33 and 35 machined from a single piece of steel, presenting the appearance or ⁸„ in Figure 10 is shown an embodiment 01 the presetinvention which utilizes crimping die features and me.h“dSosed and claimed by Mr Clyde N Hotaawl.

1ά in application Serial No. 73,MS. Hied F·”» ' ¹⁹®' ³

Figure 10 is a cross-sectional view representing the crimping of the connection shown in Figure 9; this figure is ZTogous to and on the enlarged scale or Fxgures 4 ^Referring to Figure 1, an illustrative flag-type terminal I _is “wiS 3 Lw 24 ..Λ· ·Μ· «‘ΐ tongue 24 being integrally attached to a metallic terrule 22 This type of terminal is preferably made by sia. p in® a ferrule and tongue-forming portion rolling up the former until its edge 25 abuts against, the juncture 26 ) between ferrule and side element 24. In many applications, as where great strength and/or ^reslsta“^ceJ?J^b| effect of corrosive fluids is desired, this abutment 26 is filled with a sealing and bonding compound, such as hard solder, referred to generally as brazing m^at^ena1· Figure 2 shows this assembly with the rerrule ρ,.πκ.η -2 enclosed by a sheath 28 of plastic insulation n“^aiaccording to the above-referred to copending application nf Trueman R. Beits. , . j

As there disclosed, the insulation sheath is advantageously extended beyond one end of the lerrule an crimped onto the conductor insulation to suppoxt toconductor and strengthen the wire against «oration and flexure Such an extension is shown in Figure - and Figures 5 6, and 9 such extensions are shown compressed onto the insulated wire 30 by means of the advantageous hexagonally-shaped crimp 29 disclosed and claimed m the Carlson Patent No. 2,359,083. Further, the insulation sheath may be cemented to the ferrule to enhanc the duality of the assembly. . ,

Prior to the present invention, such flag-type terminals would be crimned onto a wire by compressing their errute portions 22 (insulated or bare) between die surfaces in a fashion which flattened the terminal toward the plane of the side element (e. g., tongue 24). An illustrative crime of this type is shown in Figure 3, wnerem an insulated terminal (as shown in Figure 2) has been crimpe onto a wire 30 by die surfaces which create D-shaped curved, impressions 32. This crimp and the method of making it are more fully disclosed and claimed in the Patent No. 2,554,813 issued to Stephen N. Buchanan on May 29 1951; it is a crimp well adapted to create ferruleand-wire junctions of great strength and electrics» and mechanical stability, both on bare as well as cnmpaffiyinsulated terminals. However, when used on flag-type terminals, the die impressions 32 tend to increase thlateral width W by extruding ths rerrule (and msalation if there is such) material laterally outward from the free end of the tongue 24. Oftentimes this increase in lateral dimension is restrictive of the use of such terminals, particularly of those with insulation sheath 23. Also as shown in Figure 4, this causes outward extrusion of the seam, 26, tending to cam it open, thus causing terminal failure. .

In this application the various directions, dimensions and reference planes are designated as follows:

“Lateral” is the direction in which the width W

Figure 3 is taken. .„ “Longitudinal” is the direction of the length L “Vertical is the direction perpendicular to both lateral and longitudinal dimensions.

“Lateral axis” is the line through the center of the s de element of the terminal perpendicular to the axis of the ferrule portion. _,· ‘“Longitudinal axis” is the axis of the ferrule portion Ox the terminal., , “Vertical axis” is the line through the center of the ferrule portion perpendicular to the lateral plane.

“Lateral plane” is the plane common to the lateral and longitudinal axes..

“Vertical plane” is the plane common to the longitudinal and vertical axes._

Note the difference between Figure, 3 and Figures 3 io on on the place.

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9,740,102 ίοϊώΤ ^{ίΠ FigUr}v ^Ι0’ ^{one of the} Holteapple dies is dotted to receive the side element of a flag^P terminal face «Tn ^{three Smoothly c: rved die} surfaces, one surface 4/ boine on a ram 46, tne other two in a channellike member 48 having side walls 50 which extend from he curveu surfaces 51 and 52 in parallel relationship for short distances away from these surfaces. As shown in Figure 9 this crimp produces a somewhat elongated elliptical bana »4 of compressed material in the insulated material ^W!*p^SUbSt^ian?^{aliy transverse} extrusion of this matenaJ; he extrusion or the metal ferrule 22 (Figure 1), and insulation material 28 which occurs durin* crimpthl na ™^!tedi’ “ ^th!S K^irmp’ ^{to a lon}2itudinal flow alofg the nairow clearance between the ferrule and the die, as the feirule and insulation sheath are substantially conThe dfeT T ^pecT^{hery of the band} under compression. The die surfaces 51 and 52 may advantageously be machined from a single block of tool steel.

The above discussions have contemplated the use of HowX^teth^“^{alS baViDg}· ^flat’ ^tongue'^Iike&gt; ^side elements. · Howeve., the invention is not limited to such flat ele^S’4^{S tle} ?^lsarance between die surfaces 37 and surfaces e9 may be adapted to fit may other side elements e. g., pm-type or blade-like plugs.

crimr,T_PT^bOdi?^ent Τ'™ “ ^{FigUre 10}’ ^ths conflnedth/t thP t™^{ay 01 e}J^ongaied longitudinal extent so that the entire end, or the entire length, of a terminal the^rfl ^e«^and!i^Orii“^{SUlatlOn Sheath would be} compressed to the flattened elliptical shape shown in the crimped area m Figure 9 Such an elongated crimp would be easier to remove from the dies as the sleeve would then be tions^f Τ’’ ^at' T^{ar tO} °^{De end}’ ^{and no flare}d portions of the original sheatn dimension would remain to WiTh ^b5^tmg,^ths «imped terminal from the die. With such dies, the terminal could be merely slid longitudinally out of the female die.